Rapid informational prototypes, including rapid colored prototypes

• US 6,654,656 B2
• Filed: 03/06/2001
• Issued: 11/25/2003
• Est. Priority Date: 03/06/2001
• Status: Expired due to Fees

• Current Assignee: Rutgers University
• Original Assignee: The Research Foundation for The State University of New York (State University of New York)
• Inventors: Stalis, Kirk C., Kesavadas, Thenkurussi
• Primary Examiner(s): Picard, Leo
• Assistant Examiner(s): Swindell, W Russell
• Application Number:
  US09/799,953
• Publication Number:
  US 20030167099A1
• Time in Patent Office: 994 Days
• Field of Search: 703/1, 703/6, 703/7, 700/97, 700/98, 700/118, 700/119, 700/120, 700/163, 700/183, 345/419, 345/420
• US Class Current: 700/119
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: G16Z 99/00 Subject matter not provided for in other main groups of this subclass

Abstract

The disclosure relates to rapid informational prototypes of three-dimensional objects and systems having three or more dimensions, wherein the informational prototype includes information beyond outer physical shape, such as stress contours, thermal gradients, internal structures and elements, and elements varying with time. One preferred manner for indicating information is through the use of differently colored regions in the prototype. According to a rapid prototyping method of the present invention, a series of slices through the object or system are defined by an ordinal number, overall contour information for describing shape of the slice in an X-Y plane, slice thickness information for describing thickness of the slice in a Z direction, and slice image information for providing useful information other than the overall contour information, preferably through color images. The method further involves cutting or otherwise extracting a plurality of layers corresponding to the defined slices from stock material, such as transparent plastic, and applying corresponding slice image information to the layers either before or after they are extracted. The layers are stacked based on the ordinal numbers of the corresponding slices to form the informational prototype. A tab is preferably added to the contour information of each slice to facilitate manipulation of the individual layers as well as the completed informational prototype. A data file format is also disclosed for storing a representation of a rapid informational prototype in an information medium. The data file format generally comprises a file header for identifying the data file, a body segment for registering a plurality slice images with a plurality of slices taken through the object or system, and a plurality of slice segments for indicating an overall contour and a thickness for each of the slices.

Claims

1. A method of manufacturing an informational prototype of a three-dimensional object comprising the steps of:

(A) defining a plurality of slices through said object, each of said slices being defined by an ordinal number, overall contour information for describing shape of said slice in an X-Y plane, slice thickness information for describing thickness of said slice in a Z direction, and slice image information;

(B) extracting a plurality of layers from stock material, each of said plurality of layers corresponding to a respective one of said plurality of slices;

(C) applying corresponding slice image information to said plurality of layers; and

(D) stacking said plurality of layers based on said ordinal numbers of said plurality of slices to form said informational prototype.

2. The method according claim 1, wherein tab contour information is added to said overall contour information for each of said plurality of slices, whereby each of said plurality of layers includes a tab.

3. The method according to claim 2, comprising the further step of fastening said tabs together.

4. The method according to claim 3, wherein said tabs are fastened together by adhesive.

5. The method according to claim 3, wherein said tabs are fastened together by a mechanical fastener.

6. The method according to claim 1, wherein said slice image information is applied to said stock material by exposing said stock material to radiation.

7. The method according to claim 1, wherein said slice image information is applied to said stock material by fused deposition of colored material.

8. The method according to claim 1, wherein said slice image information is applied to said stock material by printing.

36. A prototype formed by the method of claim 1, said method comprising the steps of:

(A) defining a plurality of slices through said object, each of said slices being defined by an ordinal number, overall contour information for describing shape of said slice in an X-Y plane, slice thickness information for describing thickness of said slice in a Z direction, and slice image information;

(B) extracting a plurality of layers from stock material, each of said plurality of layers corresponding to a respective one of said plurality of slices;

(C) applying corresponding slice image information to said plurality of layers; and

(D) stacking said plurality of layers based on said ordinal numbers of said plurality of slices to form said informational prototype.

38. The method recited in claim 1 wherein said slice information comprises thermal gradients, stress contours, internal elements, or time dependent changes.

9. A method of manufacturing an informational prototype of a system having at least three dimensions comprising the steps of:

(A) defining a plurality of slices taken along a Z dimension of said system, each of said slices being defined by an ordinal number, overall contour information for describing shape of said slice in an X-Y dimensional plane, slice thickness information for describing thickness of said slice in said Z dimension, and slice image information;

(B) extracting a plurality of layers from stock material, each of said plurality of layers corresponding to a respective one of said plurality of slices;

(C) applying corresponding slice image information to said plurality of layers; and

(D) stacking said plurality of layers based on said ordinal numbers of said plurality of slices to form said informational prototype.

10. The method according claim 9, wherein tab contour information is added to said overall contour information for each of said plurality of slices, whereby each of said plurality of layers includes a tab.

11. The method according to claim 10, comprising the further step of fastening said tabs together.

12. The method according to claim 11, wherein said tabs are fastened together by adhesive.

13. The method according to claim 11, wherein said tabs are fastened together by a mechanical fastener.

14. The method according to claim 9, wherein said slice image information is applied to said stock material by exposing said stock material to radiation.

15. The method according to claim 9, wherein said slice image information is applied to said stock material by fused deposition of colored material.

16. The method according to claim 9, wherein said slice image information is applied to said stock material by printing.

37. A prototype formed by the method of claim 9, said method comprising the steps of:

(A) defining a plurality of slices taken along a Z dimension of said system each of said slices being defined by an ordinal number, overall contour information for describing shape of said slice in an X-Y dimensional plane, slice thickness information for describing thickness of said slice in a Z dimension, and slice image information;

(B) extracting a plurality of layers from stock material, each of said plurality of layers corresponding to a respective one of said plurality of slices;

(C) applying corresponding slice image information to said plurality of layers; and

(D) stacking said plurality of layers based on said ordinal numbers of said plurality of slices to form said informational prototype.

39. The method recited in claim 9 wherein said slice information comprises thermal gradients, stress contours, internal elements, or time dependent changes.

17. An information medium having a data file representative of an informational prototype of a three-dimensional object, said data file comprising:

a file header for identifying said data file;

a body segment for registering a plurality slice images with a plurality of slices taken through said object; and

a plurality of slice segments for indicating an overall contour and a thickness for each of said plurality of slices;

wherein each of said plurality of slice images indicates slice image information.

18. The information medium according to claim 17, wherein said plurality of slice images represents physical objects in said three-dimensional object.

19. The information medium according to claim 17, wherein said plurality of slice images represents a physical characteristic of said three-dimensional object.

20. The information medium according to claim 19, wherein said physical characteristic is a thermal gradient.

21. The information medium according to claim 19, wherein said physical characteristic is a stress contour.

40. The information medium recited in claim 17 wherein said slice information comprises thermal gradients, stress contours, internal elements, or time dependent changes.

22. An information medium having a data file representative of an informational prototype of a system having at least three-dimensions, said data file comprising:

a file header for identifying said data file;

a body segment for registering a plurality slice images with a plurality of slices taken along a Z-dimension of said system; and

a plurality of slice segments for indicating an overall contour and a thickness for each of said plurality of slices;

wherein each of said plurality of slice images indicates slice image information.

23. The information medium according to claim 22, wherein said Z-dimension is time.

41. The information medium recited in claim 22 wherein said slice information comprises thermal gradients, stress contours, internal elements, or time dependent changes.

24. An informational prototype of a three-dimensional object comprising:

a plurality of stacked layers corresponding to a plurality slices taken through said object, each of said plurality of layers having an overall contour and a thickness; and

a plurality of slice images applied to said plurality of layers, each of said plurality of slice images providing slice image information.

25. The informational prototype according to claim 24, wherein each of said plurality of layers includes a tab as part of said overall contour of said layer, and said tabs are fastened together.

26. The informational prototype according to claim 24, wherein said stacked layers are formed from a transparent stock material.

27. The informational prototype according to claim 24, wherein said plurality of slice images includes color images.

28. The informational prototype according to claim 24, wherein said plurality of slice images represent gradients of a physical property of said object.

29. The informational prototype according to claim 28, wherein said physical property is temperature.

30. The informational prototype according to claim 28, wherein said physical property is stress.

42. The informational prototype recited in claim 24 wherein said slice information comprises thermal gradients, stress contours, internal elements, or time dependent changes.

31. An informational prototype of a system having at least three-dimensions comprising:

a plurality of stacked layers corresponding to a plurality slices taken along a Z-dimension of said system, each of said plurality of layers having an overall contour and a thickness; and

a plurality of slice images applied to said plurality of layers, each of said plurality of slice images providing slice image information.

32. The informational prototype according to claim 31, wherein each of said plurality of layers includes a tab as part of said overall contour of said layer, and said tabs are fastened together.

33. The informational prototype according to claim 31, wherein said stacked layers are formed from a transparent stock material.

34. The informational prototype according to claim 31, wherein said plurality of slice images includes color images.

35. The informational prototype according to claim 31, wherein each of said plurality of slice images corresponds to a unique moment in time.

43. The informational prototype recited in claim 31 wherein said slice information comprises thermal gradients, stress contours, internal elements, or time dependent changes.